Flexible stud welding system based on industrial robot

Abstract

The utility model discloses a flexible stud welding system based on an industrial robot. The flexible stud welding system comprises the industrial robot, a workpiece grabbing and fixing mechanism and automatic stud welding equipment. The industrial robot comprises an adjusting base and an industrial robot body. The workpiece grabbing and fixing mechanism is arranged at the tail end of the industrial robot body and comprises a main body frame, a plurality of clamping mechanisms and a sensing mechanism. The automatic stud welding equipment comprises a servo stud welding gun, a servo nail feeding assembly mechanism and a stud welding controller. Stud welding of different workpieces can be completed without replacing a gripper tool and stud welding equipment, high adaptability and flexibility are achieved, the collinear production requirement of multiple vehicle types can be met, and the beneficial effects of being stable in welding quality, high in efficiency and the like are achieved.

Description

Technical Field

[0001] This utility model belongs to the field of automotive body welding technology, specifically relating to a flexible stud welding system based on an industrial robot. Background Technology

[0002] Currently, most domestic stud welding equipment uses a single welding method in practical field applications, namely, welding with a one-to-one workpiece fixing mechanism. This method has the following problems: First, the tooling structure is complex, resulting in high equipment costs; second, because the workpiece fixing mechanism corresponds one-to-one with the welding workpiece, production efficiency is low; and finally, it is difficult to adapt to the welding needs of modern production for multiple varieties and specifications of workpieces, lacking flexibility.

[0003] Therefore, there is an urgent need to design a flexible stud welding equipment system that can be compatible with different workpieces to meet the welding needs of different product parts and improve production efficiency. Utility Model Content

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a flexible stud welding system based on an industrial robot to improve its flexibility in adapting to different vehicle models, meet the welding needs of different vehicle models, reduce tooling investment, and improve production efficiency.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A flexible stud welding system based on an industrial robot, comprising an industrial robot, including:

[0007] A workpiece gripping and fixing mechanism is disposed at the end effector of the industrial robot; and

[0008] Automatic stud welding equipment, which includes:

[0009] A servo stud welding gun is fixedly mounted on a mounting bracket.

[0010] A servo stud feeding assembly mechanism, which is connected to the servo stud welding gun via a stud feeding hose; and

[0011] A stud welding controller, which is electrically connected to the servo stud feeding assembly mechanism, is used to control the operation of the entire welding system.

[0012] In some optional embodiments of this utility model, the workpiece gripping and fixing mechanism includes:

[0013] Main framework;

[0014] Multiple clamping mechanisms are fixedly mounted on the main frame; and

[0015] The sensing mechanism is fixedly mounted on the main frame and is used to detect the position status of the workpiece.

[0016] Preferably, the clamping mechanism includes:

[0017] A tilting cylinder is fixed to the main frame;

[0018] The gripper, which is connected to the output shaft of the tilting cylinder; and

[0019] A clamping sensor, which is mounted on the gripper, is used to detect the workpiece clamping status.

[0020] Preferably, the sensing mechanism includes:

[0021] Proximity sensor;

[0022] The adjustable connection mechanism includes an X-axis adjustment mechanism and a Y-axis adjustment mechanism for adjusting the position of the proximity sensor in the X and Y directions, respectively; and

[0023] A signal processing unit, which is electrically connected to the proximity sensor, is used to convert the sensing signal into a digital signal and transmit it to the industrial robot control system.

[0024] Preferably, the sensing mechanism is used to detect the workpiece status in real time and transmit the detection signal to the industrial robot.

[0025] More preferably, the industrial robot controls the motion trajectory of the workpiece gripping and fixing mechanism based on the detection signal.

[0026] In some optional embodiments of this utility model, the servo-driven nail feeding assembly mechanism includes:

[0027] A control cabinet, used to install control components;

[0028] An operation panel, which is mounted on the control cabinet, is used for human-machine interaction.

[0029] A maintenance unit, located within the control cabinet, is used for system maintenance;

[0030] The filling valve is connected to the air source and is used to regulate air pressure;

[0031] A transport ring, located outside the control cabinet, is used for equipment handling;

[0032] A connecting plate, which is fixed to the control cabinet, is used to install the distribution components;

[0033] A dispensing component, fixed to the control cabinet via the connecting plate, is used for dispensing welding studs; and

[0034] A separating roller, connected to the dispensing component, is used to separate and convey the weld nails one by one.

[0035] In some optional embodiments of this utility model, the servo stud welding gun includes:

[0036] Bolt bracket, which is used to support the entire welding torch structure;

[0037] A slot, provided on the bolt bracket, is used to install a dirt cover;

[0038] A contamination shield, which is fixed to the bolt bracket via the slot, is used to prevent welding spatter;

[0039] The outer casing, which is fixed to the bolt bracket, is used to protect the internal structure;

[0040] A sliding block assembly, which is slidably disposed within the housing assembly, is used to enable the extension and retraction movement of the welding torch;

[0041] A supply hose interface, which is provided on the housing assembly, is used to connect a gas supply hose;

[0042] A control line interface, which is located on the housing assembly, is used to connect control signal cables;

[0043] The front and rear interfaces of the loading rod are respectively located at the front and rear ends of the housing assembly and are used to control the reciprocating motion of the loading rod.

[0044] A welding pipe interface, located at the front end of the housing assembly, is used to connect a welding cable;

[0045] The slide forward interface and slide rear interface are respectively located at the front and rear ends of the slide assembly and are used to control the reciprocating motion of the slide.

[0046] In some optional embodiments of this utility model, the stud welding controller includes:

[0047] The main switch for the equipment is located on the front panel of the controller and is used to control the power supply of the entire system.

[0048] The operation panel, located on the front panel of the controller, is used for parameter setting and status display;

[0049] The key switch, located on the front panel of the controller, is used for system access control.

[0050] The equipment door, located in front of the controller, is used for maintenance and repair.

[0051] A transport ring, located outside the controller, is used for equipment handling;

[0052] LED indicator lights, located on the front panel of the controller, are used to display the fuse status;

[0053] An RS232 computer interface, located on the side of the controller, is used for communication with an external computer.

[0054] A terminal interface, located on the side of the controller, is used to connect external control devices; and

[0055] The conveyor roller, located at the bottom of the controller, is used for moving the equipment.

[0056] In some optional embodiments of this utility model, the servo feeding component mechanism is fixedly mounted on the stud welding controller and electrically connected to the stud welding controller via a cable.

[0057] In some optional embodiments of this utility model, the industrial robot is used to control the workpiece gripping and fixing mechanism to grip the workpiece and move it to the servo stud welding gun for welding.

[0058] In some optional embodiments of this utility model, the industrial robot sends a welding signal to the automatic stud welding equipment at a preset node.

[0059] In some optional embodiments of this utility model, the industrial robot adopts a six-axis robotic arm; the workpiece gripping and fixing mechanism is connected to the end of the six-axis robotic arm.

[0060] The beneficial effects of this utility model are:

[0061] 1. The flexible stud welding system of this utility model adopts a combination of industrial robot and workpiece gripping and fixing mechanism, which can complete stud welding of different workpieces without changing the gripper tool and stud welding equipment, and has strong adaptability and flexibility.

[0062] 2. This utility model uses an industrial robot driven by a gripper to grasp the workpiece. The gripping space is flexible, the walking speed is precisely controllable, and the operation is stable.

[0063] 3. This utility model uses an inductive proximity magnetic sensor in conjunction with an adjustable mounting bracket, which can automatically locate the workpiece to be welded, shorten the debugging cycle, and has high positioning accuracy, and is simple and efficient to operate.

[0064] 4. This utility model can meet the stud welding requirements of different car models or different workpieces, reduce tooling investment costs, reduce debugging difficulty, shorten the introduction time of new car models, and realize the co-line production of stud welding for multiple car models.

[0065] 5. The welding quality of this utility model is stable and the welding efficiency is high. Attached Figure Description

[0066] To more clearly illustrate the technical solutions of the disclosed embodiments of this utility model, the accompanying drawings of the embodiments will be briefly described below. These drawings are for illustrative purposes only and are not intended to limit the scope of protection of this utility model.

[0067] Figure 1 This is an axial view of the servo-feeding component mechanism in the stud welding system of this utility model embodiment;

[0068] Figure 2 This is an axial view of the workpiece gripping and fixing mechanism in the stud welding system of this utility model embodiment;

[0069] Figure 3 This is an isometric view of the servo stud welding gun mechanism in the stud welding system of this utility model embodiment;

[0070] Figure 4 This is an isometric view of the stud welding controller in the stud welding system of this utility model embodiment. Detailed Implementation

[0071] The technical solution (including preferred technical solution) of this utility model will be further described in detail below with reference to the accompanying drawings and by listing some optional embodiments. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.

[0072] Example 1

[0073] like Figures 1-4 As shown, this embodiment provides a flexible stud welding system based on an industrial robot, including an industrial robot, an automatic stud welding device, and a workpiece gripping and fixing mechanism 300.

[0074] The industrial robot consists of an adjustment base and the robot body. The adjustment base is installed on the ground, and the robot body is fixed to the adjustment base. By adjusting the level and position of the base, the accuracy of the robot body's spatial coordinates in the working environment can be ensured.

[0075] The workpiece gripping and fixing mechanism 300 is installed at the end of the industrial robot body. The workpiece gripping and fixing mechanism 300 includes a main frame 301, multiple clamping mechanisms 302, 303, and 304, and a sensing mechanism 305. The clamping mechanisms 302 to 304 and the sensing mechanism 305 are all fixed to the main frame 301 by bolts; the sensing mechanism 305 is used to detect the position status of the workpiece.

[0076] Each clamping mechanism includes: a tilting cylinder fixed to the main frame; a gripper connected to the output shaft of the tilting cylinder; and a clamping sensor disposed on the gripper for detecting the workpiece clamping status.

[0077] In some optional embodiments of this invention, the tilting cylinder is fixed to the main frame, and its output shaft is connected to the gripper. The gripper adopts a V-shaped structure design, which can accommodate workpieces of different diameters. A clamping sensor is installed on the gripper to detect whether the workpiece is correctly clamped. When it is necessary to clamp the workpiece, the tilting cylinder drives the gripper to rotate, and the gripper clamps the workpiece by controlling the air pressure. The clamping sensor monitors the clamping status in real time to ensure that the workpiece is firmly clamped.

[0078] The sensing mechanism 305 includes: a proximity sensor; an adjustable connection mechanism including an X-axis adjustment mechanism and a Y-axis adjustment mechanism for adjusting the position of the proximity sensor in the X and Y axes; and a signal processing unit electrically connected to the proximity sensor for converting the sensing signal into a digital signal and transmitting it to the industrial robot control system. The adjustable connection mechanism enables precise positioning of the proximity sensor in space, thereby ensuring accurate sensing of the workpiece.

[0079] In some embodiments of this invention, the sensing mechanism includes a proximity sensor, an X-axis adjustment mechanism, a Y-axis adjustment mechanism, and a signal processing unit. The X-axis and Y-axis adjustment mechanisms employ a slider guide structure, allowing precise adjustment of the proximity sensor's position in both directions via fastening bolts. The proximity sensor is an inductive sensor capable of detecting the presence of a metal workpiece and outputting a signal. The signal processing unit converts the sensor's detection signal into a digital signal, which is transmitted to the industrial robot control system via a communication interface. Furthermore, the sensing mechanism is equipped with a position calibration device to determine the optimal sensing position during the commissioning phase.

[0080] In some embodiments of this invention, the sensor 305 is used to detect the workpiece status in real time and transmit the detection signal to the industrial robot. The industrial robot controls the movement trajectory of the workpiece gripping and fixing mechanism based on the detection signal.

[0081] An automatic stud welding device includes: a servo stud welding gun 400, which is fixedly mounted on a mounting bracket; a servo stud feeding assembly mechanism 200, which is connected to the servo stud welding gun 400 via a stud feeding hose; and a stud welding controller 500, which is electrically connected to the servo stud feeding assembly mechanism 200 and is used to control the operation of the entire welding system.

[0082] The servo-driven nail feeding assembly mechanism 200 includes: a control cabinet 201 for mounting control components; an operation panel 202 mounted on the control cabinet 201 for human-machine interaction; a maintenance unit 203 located inside the control cabinet for system maintenance; a filling valve 204 connected to an air source for regulating air pressure; a transport ring 205 located outside the control cabinet for equipment handling; a connecting plate 206 fixed to the control cabinet for mounting a distribution component; a distribution component 207 fixed to the control cabinet via the connecting plate for distributing welding nails; and a separating roller 208 connected to the distribution component for separating and conveying welding nails one by one.

[0083] The servo stud welding torch 400 includes: a bolt bracket 401 for supporting the entire torch structure; a slot 402 for mounting a contaminant cover on the bolt bracket; a contaminant cover 403 fixed to the bolt bracket via the slot for preventing welding spatter; a housing assembly 404 fixed to the bolt bracket for protecting the internal structure; a slide assembly 405 slidably disposed within the housing assembly for enabling the telescopic movement of the welding torch; a supply hose interface 406 disposed on the housing assembly for connecting a gas supply hose; a control line interface 407 disposed on the housing assembly for connecting a control signal cable; a loading rod forward interface and a loading rod backward interface 412 disposed on the housing assembly for controlling the reciprocating movement of the loading rod; a welding pipe interface 409 disposed on the housing assembly for connecting a welding cable; and a slide forward interface 410 and a slide backward interface 411 disposed on the slide assembly for controlling the reciprocating movement of the slide. The tail of the welding torch is connected to the servo stud feeding assembly 2 via a stud feeding hose and a control cable to enable signal transmission and stud feeding.

[0084] The working process of the servo stud welding gun 400 is as follows:

[0085] 1. Before welding begins, the control signal is transmitted to the welding torch control system through the control line interface;

[0086] 2. The system controls the slide assembly for positioning via the slide forward interface and the slide backward interface;

[0087] 3. The stud is conveyed to the position via the forward interface of the loading rod, and the loading rod is reset by the backward interface;

[0088] 4. Supply air pressure through the hose interface to ensure stable pressure during the welding process;

[0089] 5. Welding current is input through the welding pipe interface to achieve stud welding;

[0090] 6. Throughout the process, the anti-fouling cover effectively prevents welding spatter from affecting the normal operation of the equipment.

[0091] The stud welding controller 500 includes: a main switch 501, located on the front panel of the controller, for controlling the power supply of the entire system; an operation panel 502, located on the front panel of the controller, for parameter setting and status display; a key switch 503, located on the front panel of the controller, for system access control; a door 504, located at the front of the controller, for maintenance and repair; a transport ring 505, located outside the controller, for equipment handling; an LED indicator 506, located on the front panel of the controller, for displaying fuse status; an RS232 computer interface 507, located on the side of the controller, for communication with an external computer; a terminal interface 508, located on the side of the controller, for connecting external control equipment; and a conveyor roller 509, located at the bottom of the controller, for equipment movement.

[0092] This invention enables stud welding without altering the gripper fixture or replacing the stud welding equipment. It utilizes an industrial robot driven by a gripper to grasp the workpiece, offering flexible gripping space, precise and controllable movement speed, and stable operation. Employing an inductive proximity magnetic sensor in conjunction with an adjustable mounting bracket, it automatically locates the workpiece to be welded, shortening the debugging cycle and providing extremely high positioning accuracy. It is simple and efficient, suitable for stud welding of various vehicle models or different workpieces. It reduces tooling investment, simplifies debugging, significantly improves its adaptability to different vehicle models, shortens the introduction time for new models, and can support multi-model stud welding on a single production line. The equipment delivers stable welding quality and high welding efficiency.

[0093] Example 2

[0094] Based on Example 1, this example details the working process of the system:

[0095] 1. After the workpiece is in place, the industrial robot controls the workpiece gripping and fixing mechanism 300 to grip the workpiece.

[0096] 2. When the proximity sensor on the workpiece gripping and fixing mechanism 300 detects the workpiece, the industrial robot sends a signal to the automatic stud welding equipment.

[0097] 3. After receiving the signal, the automatic stud welding equipment performs pre-preparation of the equipment.

[0098] 4. The industrial robot moves along a preset trajectory, moving the workpiece to the welding position.

[0099] 5. During operation, the industrial robot sends a welding signal to the automatic stud welding equipment at a preset node, triggering the welding operation.

[0100] 6. The sensing mechanism 305 continuously monitors the workpiece status in real time and transmits the detection signal to the industrial robot, which then adjusts its motion trajectory based on the detection signal.

[0101] Example 3

[0102] Based on Examples 1 and 2, this example further illustrates the application scenarios of the system:

[0103] Multi-workpiece compatibility: When different workpieces need to be stud welded, there is no need to change the stud welding equipment and workpiece gripping and fixing mechanism; only the motion program of the industrial robot needs to be adjusted.

[0104] Multi-vehicle adaptability: The system can adapt to the stud welding requirements of different vehicle models, enabling multi-vehicle production on the same line. By adjusting the position of the proximity sensor and the movement trajectory of the industrial robot, welding work for different vehicle models can be quickly switched.

[0105] Flexible production: The system can flexibly adjust the welding sequence and position according to production needs, improving production efficiency. The real-time detection function of the sensing mechanism 305 ensures the stability and reliability of the welding process.

[0106] Quality control: By precisely controlling the movement of the industrial robot and the welding parameters of the automated stud welding equipment, consistent welding quality can be ensured. The various components of the system work collaboratively through signal interaction, improving welding accuracy.

[0107] When stud welding is required on workpieces of different vehicle models, there is no need to change the stud welding equipment and workpiece gripping and fixing mechanism. Only the running trajectory and preset nodes of the industrial robot need to be adjusted, which greatly improves the flexibility and production efficiency of the system.

[0108] Those skilled in the art will readily understand that the above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, combinations, substitutions, improvements, etc., made under the spirit and principles of the present utility model are included within the protection scope of the present utility model.

Claims

1. A flexible stud welding system based on an industrial robot, comprising an industrial robot, characterized in that, include: A workpiece gripping and fixing mechanism is installed at the end of the industrial robot; as well as Automatic stud welding equipment, which includes: A servo stud welding gun is fixedly mounted on a mounting bracket. A servo stud feeding assembly mechanism, which is connected to the servo stud welding gun via a stud feeding hose; and A stud welding controller, which is electrically connected to the servo stud feeding assembly mechanism, is used to control the operation of the entire welding system.

2. The flexible stud welding system based on an industrial robot according to claim 1, characterized in that, The workpiece gripping and fixing mechanism includes: Main framework; Multiple clamping mechanisms are fixedly mounted on the main frame; and The sensing mechanism is fixedly mounted on the main frame and is used to detect the position status of the workpiece. Preferably, the clamping mechanism includes: A tilting cylinder is fixed to the main frame; The gripper, which is connected to the output shaft of the tilting cylinder; and A clamping sensor, which is mounted on the gripper, is used to detect the workpiece clamping status.

3. The flexible stud welding system based on an industrial robot according to claim 2, characterized in that, The sensing mechanism includes: Proximity sensor; The adjustable connection mechanism includes an X-axis adjustment mechanism and a Y-axis adjustment mechanism for adjusting the position of the proximity sensor in the X and Y directions, respectively; and A signal processing unit, which is electrically connected to the proximity sensor, is used to convert the sensing signal into a digital signal and transmit it to the industrial robot control system.

4. The flexible stud welding system based on an industrial robot according to claim 3, characterized in that, The sensing mechanism is used to detect the workpiece status in real time and transmit the detection signal to the industrial robot; the industrial robot controls the movement trajectory of the workpiece gripping and fixing mechanism according to the detection signal.

5. The flexible stud welding system based on an industrial robot according to claim 1, characterized in that, The servo-driven pin feeding assembly mechanism includes: A control cabinet, used to install control components; An operation panel, which is mounted on the control cabinet, is used for human-machine interaction. A maintenance unit, located within the control cabinet, is used for system maintenance; The filling valve is connected to the air source and is used to regulate air pressure; A transport ring, located outside the control cabinet, is used for equipment handling; A connecting plate, which is fixed to the control cabinet, is used to install the distribution components; A dispensing component, fixed to the control cabinet via the connecting plate, is used for dispensing welding studs; and A separating roller, connected to the dispensing component, is used to separate and convey the weld nails one by one.

6. The flexible stud welding system based on an industrial robot according to claim 1, characterized in that, The servo stud welding gun includes: Bolt bracket, which is used to support the entire welding torch structure; A slot, provided on the bolt bracket, is used to install a dirt cover; A contamination shield, which is fixed to the bolt bracket via the slot, is used to prevent welding spatter; The outer casing, which is fixed to the bolt bracket, is used to protect the internal structure; A sliding block assembly, which is slidably disposed within the housing assembly, is used to enable the extension and retraction movement of the welding torch; A supply hose interface, which is provided on the housing assembly, is used to connect a gas supply hose; A control line interface, which is located on the housing assembly, is used to connect control signal cables; The loading rod has a forward interface and a rearward interface, which are respectively provided on the housing assembly and are used to control the reciprocating motion of the loading rod. A welding pipe interface, which is provided on the housing assembly, is used to connect a welding cable; The slide forward interface and slide backward interface are respectively provided on the slide assembly and are used to control the reciprocating motion of the slide.

7. The flexible stud welding system based on an industrial robot according to claim 1, characterized in that, The stud welding controller includes: The main switch for the equipment is located on the front panel of the controller and is used to control the power supply of the entire system. The operation panel, located on the front panel of the controller, is used for parameter setting and status display; The key switch, located on the front panel of the controller, is used for system access control. The equipment door, located in front of the controller, is used for maintenance and repair. A transport ring, located outside the controller, is used for equipment handling; LED indicator lights, located on the front panel of the controller, are used to display the fuse status; An RS232 computer interface, located on the side of the controller, is used for communication with an external computer. A terminal interface, located on the side of the controller, is used to connect external control devices; and The conveyor roller, located at the bottom of the controller, is used for moving the equipment.

8. The flexible stud welding system based on an industrial robot according to claim 1, characterized in that: The industrial robot uses a six-axis robotic arm; the workpiece gripping and fixing mechanism is connected to the end of the six-axis robotic arm.

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